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MMD Equipment NGK-2900H Service Manual

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SERVICE MANUAL
GENERATORS
NGK-2900H, NGK-4300H,
NGK-6000H, NGK-7000H
MMD Equipment Inc.
121 High Hill Road
Swedesboro, NJ 08085
Tel: (800) 433-1382
Fax: (856) 467-5235
www.mmdequipment.com

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Summary of Contents for MMD Equipment NGK-2900H

  • Page 1 SERVICE MANUAL GENERATORS NGK-2900H, NGK-4300H, NGK-6000H, NGK-7000H MMD Equipment Inc. 121 High Hill Road Swedesboro, NJ 08085 Tel: (800) 433-1382 Fax: (856) 467-5235 www.mmdequipment.com...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS Safety Precautions Specifications and Maintenance Schedule Repair Questionnaire Pre-Operation Checks Starting Procedures Using A.C. Electric Power Stopping Procedures Component Function GFCIs Circuit Breakers Idle Control Oil Sensor Wattage Information Extension Cord Usage Special Tools Disassembly Instructions Assembly Instructions Troubleshooting Trees Engine Generator...

  • Page 3: Safety Precautions

    SAFETY PRECAUTIONS: Your safety is very important to us. While we cannot warn you about every possible hazard associated with operating your NAC portable generator, following the precautions listed below will assist you in operating your NAC generator safely. It is the operator’s responsibility to be familiar with and to follow these important safety precautions.
  • Page 4 SPECIFICATIONS: Model NGK-2900H NGK-4300H NGK-6000H/E NGK-7000H/E Type Brushless, 2-pole, self-exciting, revolving field type Max AC output 2900W 4300W 6000W 7000W Rated AC output 2400W 3800W 5000W 6000W Rated voltage 120 V 120/240 V 120/240 V 120/240 V Rated current 20 A 31.7/15.9 A...
  • Page 5 QUESTIONS TO ASK WHEN A CUSTOMER BRINGS A GENERATOR IN FOR SERVICE What brand is the generator? ___________________________ Which model? ______________________________________ What is the serial number of the generator? ______________________________ Briefly describe the problem with the generator._____________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ When did the failure occur?______________________________________________________ Were there any tools connected to the generator when the failure occurred? Yes No Which tools were being used when the failure occurred?
  • Page 6 SERVICE QUESTIONAIRE PAGE 2 Did the circuit breaker trip? Yes No If yes, which one? 30A (left) 30A (right) Main Did you reset the circuit breaker and try to continue using the generator? Yes No If yes, did the circuit breaker trip again? Yes No If yes, how long did it take for the breaker to trip again? Immediately 30 sec.

  • Page 7: Pre-Operation Checks

    PRE-OPERATION CHECKS: Note: Before performing pre-operational checks, ensure the generator is located on a clean and level surface with the engine stopped. INSPECT THE OVERALL CONDITION OF THE GENERATOR 1. Look around the generator for signs of oil or gasoline leaks. 2.
  • Page 8 ELECTRIC START MODELS 1. Follow steps 1) through 3) of the RECOIL START section. (Disregard step 1c) 2. Insert the key into the key slot and turn it clockwise to the “START” position. 3. Release the key as soon as the engine starts (the key should automatically return to the “RUN” position).

  • Page 9: Stopping Procedures

    STOPPING PROCEDURES: 1. Ensure all appliances are turned off. 2. Place CIRCUIT BREAKERS in the “OFF” position. 3. Turn the IDLE CONTROL switch to the “OFF” position. 4. Before stopping the engine, allow it to run for at least three minutes with all appliances turned off, so the engine can cool down.

  • Page 10: Idle Control

    WHAT TO DO IF THE CIRCUIT BREAKER TRIPS: If the circuit breaker trips during operation, the generator may be overloaded or the appliance being used is defective. Add the wattage from all appliances being used on the generator. If the total wattage exceeds the RATED output of the generator, the generator is overloaded.

  • Page 11: Extension Cord Usage

    EXTENSION CORD USAGE: It important to use the proper gauge extension cord with any power tool or other electrical equipment. Improper selection of extension cords can reduce the voltage leading to your tools. Low voltage at the tool results in loss of speed and power, overheating, and possible damage to the tool. To assure the proper selection of extension cords, locate the ampere rating from the tool nameplate.

  • Page 12: Special Tools

    Special Tools Recommended: Digital Multimeter capable of measuring: • AC Voltage up to 250VAC • Frequency up to 70Hz • Capacitance up to 100µF • Resistance with: Low-Ohms range Max resolution of 0.01Ω • True RMS feature is recommended but not necessary Rotor Puller Kit (Available from NAC Construction Equipment) Part Number: K-RPK...

  • Page 15: Engine

    Troubleshooting the Generator: 1. Inspect the overall condition of the generator a. Does it appear that the generator has been properly maintained? b. Check the entire generator for damage, paying extra attention to: Frame- Look for abnormal bends, dents, or other indications that the generator has been dropped or abused (the generator should not wobble on a flat surface).
  • Page 16 3. Begin testing the generator (Continued) Test the AC voltage from ALL receptacles. i) The voltage at each GFCI and the 120V/30A twist-lock receptacles should be between 124~132VAC. ii) The voltage at the 240V twist-lock should be as follows: • Ground ~ X hot = 124~132 VAC •...
  • Page 17 No or Low Voltage (Continued) (3) If the voltage is still low at the receptacles, the defective component is in the Control Panel. (a) Test the Circuit Breakers. (i) Disconnect the Circuit Breaker and check for continuity. 1. When the Circuit Breaker is “ON” there should be continuity between the terminals.
  • Page 18 Megger Tester. The insulation resistance should be greater that 10MΩ. (a) Replace any component that fails the insulation test. ROTOR MODEL RESISTANCE 3.25 ~ 4.0 Ω NGK-2900H 4..9 ~ 6.0 Ω NGK-4300H 5.5 ~ 6.7 Ω NGK-6000H/HE 5.9 ~7.2 Ω NGK-7000H/HE...
  • Page 19 5. Idle Control a) If the engine will not idle down when the switch is ON. i) Test the engine solenoid (1) Ensure the solenoid connectors are not loose. (2) Disconnect the 2P connector at the Solenoid. (3) Connect the Green/White wire to the positive (+) terminal of a 6.0 V battery and the Green wire to the negative (-) terminal.
  • Page 21 NGK-2900H WIRING DIAGRAM...
  • Page 22 NGK-4300H WIRING DIAGRAM...
  • Page 23 NGK-6000H WIRING DIAGRAM...
  • Page 24 NGK-7000H WIRING DIAGRAM...
  • Page 25 NGK-6000HE WIRING DIAGRAM...
  • Page 26 NDK-4100YE WIRING DIAGRAM...
  • Page 27 NDK-6000YE WIRING DIAGRAM...
  • Page 28 NGK-7000HE WIRING DIAGRAM...

  • Page 31: Torque Values

    Torque Values for Bolts: Size Torque Value Remarks 0.4 ~ 0.6 ft/lbs. (To attach plastic End Cover) 0.8 ~ 1.8 ft/lbs. (Other than plastic End Cover) 1.3 ~ 2.9 ft/lbs. 3.6 ~ 5.8 ft/lbs. 15 ~ 18 ft/lbs. (To attach Rotor to engine crankshaft) 11 ~ 18 ft/lbs.

This manual is also suitable for:

Ngk-4300hNgk-6000hNgk-7000h

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